Rotary dies

If a project has very long runs requiring clean and consistent hole evacuation or materials that are difficult to cut, a rotary punching unit should be considered as an alternative to diecutting, recommends the supplier. Punch units can be designed and made for platform mounting or as modules that can be placed in the press die station. To remove waste, a vacuum system can be attached to the die cylinder or rings, and the punched pieces are removed as the press is running.

TOOLS & PRODUCTION, INC., 626/286-0213, fax: 626/286-3398, www.toolsandproduction.com

A new machine technology for the in-line diecutting, creasing, or punching of a wide variety of paperboard is available in section or module designs with variable repeat. It can be integrated into new printing or converting presses or retrofitted into existing presses for processing paperboard or board and film/foil laminates for rigid packaging containers. The design accommodates web widths of up to 80 in. at servo-driven speeds of up to 2,000 fpm (which requires the temperature control of lubrication fluids and ambient temperature.) Special bearing applications and electronic components allow for micrometric depth adjustments and guarantee that set parameters are maintained. This allows for partial controlled depth cutting for “easy open” features. Innovative waste removal systems are available.

SCHOBER USA, 513/489-7393, fax: 513/489-7485, www.schoberusa.com

Co.'s mechanical method for mounting flexible die plates is said to completely eliminate magnetic cylinders. It offers 5-min setup with micrometer registration. The Eagle 360 offers tool steel flexible plate dies and modification-free installation in any rotary press. These flexible die plates are CNC machined and provide .001-in. precision for cutting, creasing and embossing on a one-station pair of die plates. The die plates provide all the advantages of solid rotary dies with the economy of plate dies. Blade heights up to .035 in. allow for cutting heavier materials.

EAGLE ROTARY SYSTEMS, INC., 517/783-2500, fax: 517/780-4996, www.EagleRotary.com

Co. offers the application-oriented CNC and EDM solid rotary dies. The CNC series includes the RD80, which is designed for most pressure-sensitive applications, and the RD90, which is heat-treated to a higher degree of hardness than the RD80 to be able to handle longer runs and some metal-to-metal cutting. The RD100 is designed for multiple-layer expanded content labels and other materials such as unsupported films, foam and medical applications. The RD200 is recommended for thinner film materials. In the EDM series, the MU100 is effective for metal-to-metal applications and long-run pressure-sensitive jobs, as well as for cutting intricate shapes and designs.

ROTOMETRICS, 800/325-3851, fax: 800/ROTO-DIE, www.rotometrics.com

Machine-sharpened dies offer advantages, demonstrated in a real-world test by a major Milwaukee converter cutting a thin film containing titanium dioxide—a hand-sharpened die lasted only 15,000 lineal ft, while a competitor's machine-sharpened die lasted 42,000 lineal ft. Co.'s product ran 105,000 lineal ft. Machine sharpening produces a precise, constant, dead-sharp blade along every inch of the die, unlike hand-sharpened dies where sharpness varies depending on the human sharpener, the intricacy of the pattern, and how many times the die has been sharpened. Consistent blades allow wear-resistant coatings to be applied evenly so that cut quality is maintained along the entire die. All the machine-sharpened dies are hardened to 58-60 Rockwell. Machine sharpening is available on several steel types including fully-hardened tool steel.

WILSON MANUFACTURING CO., 800/634-5248, fax: 800/634-5349, www.wilsonmfg.com

Co.'s new RP® dies provide significantly longer rotary-die life and like-new cutting quality through the use of shearing blades on the upper and lower die, co. says. These dies can reportedly make 15 million to 350 million revolutions before needing to be resharpened, and according to co., one folding-carton converter had passed the 1-billion revolutions mark before its dies needed resharpening. The RP rotary dies can be used with web widths from 6 to 70 in. and cut material thickness up to 0.125 in. They are said to handle paperboard, high-density plastics, masonite, corrugated, recycled and coated boards.

BERNAL, INC., 800/BERNAL-1, Fax: 248/299-3601, www.bernaltech.com